A transfer sheet and a method for manufacturing the same, a method for manufacturing a molded body using the transfer sheet and the molded body, and a front panel and an image display device using the molded body.

Abstract

To provide a manufacturing method of a transfer sheet capable of giving sufficient functionality to adherend.SOLUTION: A manufacturing method of a transfer sheet performs the following steps (1) to (2) below in order: (1) a step of forming a transfer layer including at least one functional layer by applying liquid for forming a transfer layer over a release substrate 1; and (2) a step of obtaining a transfer sheet A constituting the release substrate 1, the transfer layer, and the release substrate 2 in this order by laminating a release substrate 2 on the transfer layer in which peeling strength 2 between the release substrate 2 and the transfer layer is greater than peeling strength 1 between the release substrate 1 and the transfer layer.SELECTED DRAWING: None

Claims

1. A method for manufacturing a transfer sheet A, comprising performing the following steps (1) to (2) in order. (1) A step of applying a coating liquid for forming a transfer layer onto a release substrate 1 to form a transfer layer including at least one functional layer. At least one of the functional layers is an antifouling low refractive index layer comprising a binder resin, hollow silica particles, non-hollow silica particles, and an antifouling agent, wherein the antifouling agent is unevenly distributed on the side opposite to the release substrate 1, and the ratio X2 / X1, which is the ratio of the concentration of the antifouling agent at the interface on the side opposite to the release substrate 1 to the concentration of the antifouling agent at the interface on the release substrate 1 side, is 10 or more, the hollow silica particles and the non-hollow silica particles have their surfaces coated with a silane coupling agent, and the binder resin comprises a cured product of an ionizing radiation-curable resin composition containing an alkylene oxide-modified (meth)acrylate compound having two ethylenically unsaturated bonding groups. (2) A step of obtaining a transfer sheet A having the release substrate 1, the transfer layer and the release substrate 2 in this order, wherein the peel strength 2 between the release substrate 2 and the transfer layer is greater than the peel strength 1 between the release substrate 1 and the transfer layer.

2. Furthermore, a method for manufacturing transfer sheet B, comprising the following step (3). (3) A step of peeling the release substrate 1 from the transfer sheet A obtained by the method for manufacturing the transfer sheet A described in claim 1, to obtain a transfer sheet B having the transfer layer on the release substrate 2.

3. A method for manufacturing a molded article, comprising the following steps (4) to (5) in order. (4) A step of obtaining a laminate C in which the transfer layer side surface of the transfer sheet B obtained by the method for manufacturing the transfer sheet B according to claim 2 is in close contact with the adherend. (5) A step of peeling the release substrate 2 from the laminate C to obtain a molded body having a transfer layer on the adherend.

4. A transfer sheet A comprising a release substrate 1, a transfer layer, and a release substrate 2 in this order, wherein the peel strength 2 between the release substrate 2 and the transfer layer is greater than the peel strength 1 between the release substrate 1 and the transfer layer, the transfer layer includes at least one functional layer, at least one of which is an antifouling low refractive index layer containing a binder resin, hollow silica particles, non-hollow silica particles, and an antifouling agent, and the antifouling low refractive index layer is such that the antifouling agent is unevenly distributed on the side of the release substrate 2. A transfer sheet A wherein the ratio X2 / X1, which is the ratio of the concentration of the antifouling agent at the interface on the release substrate 2 side to the concentration of the antifouling agent at the interface on the opposite side of the release substrate 2, is 10 or more, the hollow silica particles and the non-hollow silica particles are coated on the surface with a silane coupling agent, and the binder resin contains a cured product of an ionizing radiation-curable resin composition having two ethylenically unsaturated bonding groups that have been modified with alkylene oxide.

5. The transfer sheet A according to claim 4, wherein the difference between the peel strength 2 and the peel strength 1 is 15 mN / 25 mm or more and 450 mN / 25 mm or less.

6. A transfer sheet B comprising a transfer layer on a release substrate 2, wherein the transfer layer includes at least one functional layer, at least one of which is an antifouling low refractive index layer containing a binder resin, hollow silica particles, non-hollow silica particles, and an antifouling agent, wherein the antifouling agent in the antifouling low refractive index layer is unevenly distributed on the release substrate 2 side, and the ratio X2 / X1, which is the ratio of the concentration of the antifouling agent at the interface on the release substrate 2 side to the concentration of the antifouling agent at the interface on the opposite side of the release substrate 2, is 10 or more, the hollow silica particles and the non-hollow silica particles have their surfaces coated with a silane coupling agent, and the binder resin comprises a cured product of an ionizing radiation curable resin composition containing an alkylene oxide-modified (meth)acrylate compound having two ethylenically unsaturated bonding groups.

7. A molded article comprising a transfer layer on an adherend, wherein the transfer layer comprises at least one functional layer, at least one of which is an antifouling low refractive index layer containing a binder resin, hollow silica particles, non-hollow silica particles, and an antifouling agent, wherein the antifouling low refractive index layer has the antifouling agent unevenly distributed on the side opposite to the adherend, and the ratio X2 / X1, which is the ratio of the concentration of the antifouling agent at the interface on the side opposite to the adherend to the concentration of the antifouling agent at the interface on the adherend side, is 10 or more, the hollow silica particles and the non-hollow silica particles have their surfaces coated with a silane coupling agent, and the binder resin comprises a cured product of an ionizing radiation curable resin composition containing an alkylene oxide-modified (meth)acrylate compound having two ethylenically unsaturated bonding groups.

8. The molded article according to claim 7, wherein the adherend is one selected from glass, ceramics, and resin, or a mixture thereof.

9. The molded article according to claim 7 or 8, wherein the adherend is glass, and the layer located closest to the adherend among the layers constituting the transfer layer contains a resin having one or more functional groups selected from carboxyl groups and methoxy groups.

10. A front panel for an image display device, comprising a molded body according to any one of claims 7 to 9.

11. An image display device having a front panel on a display element, wherein the front panel is a molded body according to any one of claims 7 to 9.

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